Applying measurement, control and automation to a dry corn milling ethanol production process to maximize the recovery of ethanol and co-products

ABSTRACT

Apparatus features a signal processor or signal processing module configured to: receive signaling containing information about about a measurement of one or more constituents of an output stream from a centrifuge in a dry corn milling process, including to produce Ethanol; and determine corresponding signaling containing information about a real time feedback control of the dry corn milling process, based upon the signaling received. The signal processor or signal processing module is configured to provide the corresponding signaling as control signaling to provide the real time feedback control of the dry corn milling process.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit to provisional patent application Ser.No. 62/194,539 (712-2.423//CCS-0147), filed 20 Jul. 2015; which isincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION 1. Field of Invention

This invention relates to a technique for controlling a dry corn millingprocess; and more particularly relates to a technique for controlling adry corn milling ethanol production process.

2. Description of Related Art

A dry corn milling process is the predominant method of Ethanolproduction in North America. In operation, dry corn mills generateethanol, corn syrup and corn oil from corn via fermentation,distillation and separation processes. After the distillation phase thatfollows the corn fermentation process, two marketable/valuableby-products, corn oil and corn syrup, are produced via evaporation andseparation of the stillage by-products. Stillage processing is augmentedby emulsion breaking chemistries that improve the rate and efficiency atwhich the corn oil and corn syrup phases are separated. The separationprocess performance is monitored periodically off-line bygravimetrically measuring the purity of the corn oil and syrup streams.Using the dry corn milling process to produce Ethanol, the production ofco-products can make the difference between a profitable andunprofitable production operation.

A number of measurements are utilized in a dry corn milling process totest the efficacy of co-product production. For example, oil content inthe discharges of a cyclone separator may be tested once or twice a day.However, the results of the test may take hours, and this does notprovide a real time feedback for controlling the process. Additionally,there are a number of additional measurements that, if applied to thedry milling process, could help control and optimize the process. Theknown measurement processes in the art are carried out manually, and arenot carried out as part of an automated process.

In view of this, there is a need in the industry for a better way forcontrolling a dry corn milling process, including to produce Ethanol.

SUMMARY OF THE INVENTION

In summary, the present invention provides a combination of in-line“real-time” measurements in a dry corn milling process, so thatimmediate feedback can be provided in the dry corn milling process tooptimize the production of Ethanol and co-products, including CO² andcorn oil. The present invention provides techniques of enhancing theefficiency of ethanol fermentation, distillation and valuable by-productproduction (corn oil and corn syrup), e.g., that feature automating theethanol fermentation, distillation and separation of corn oil and cornsyrup from the stillage.

By way of example, the new and unique techniques, e.g., may include, ortake the form of, a method and/or an apparatus, to provide a real timefeedback control of a dry corn milling process, including to produceEthanol.

According to some embodiments of the present invention, the apparatusmay may feature at least one signal processor or signal processingmodule configured at least to:

-   -   receive signaling containing information about a measurement of        one or more constituents of an output stream from a centrifuge        in a dry corn milling process, including to produce Ethanol; and    -   determine corresponding signaling containing information about a        real time feedback control of the dry corn milling process,        based upon the signaling received.

The apparatus may include one or more of the following additionalfeatures:

The signal processor or processing module may be configured to providethe corresponding signaling, e.g., as control signaling to provide thereal time feedback control of the dry corn milling process.

The one or more constituents of the output stream may be selected fromthe following group: corn oil, corn syrup, one or more proteins, andleftover yeast solids.

The measurement of the one or more constituents of the output stream maybe selected from the following group: the purity of corn oil in theoutput stream, including the fat content; the purity of the syrup in theoutput stream, including the carbohydrate content; the amount of proteinin the output stream, including proteins useful in animal foods; theamount of water in the output stream; and the amount of leftover yeastsolids in the output stream.

The measurement of the one or more constituents of the output stream maybe based upon an optical interrogation of the output stream.

The optical interrogation of the output stream may include processingoptical signaling provided and/or sensed in relation to the outputstream.

The optical interrogation of the output stream may include using anear-infrared spectroscopy technique for optically interrogating theoutput stream.

The optical interrogation of the output stream may include using a Ramanoptical scattering technique for optically interrogating the outputstream.

The apparatus may include an optical measurement/interrogation deviceconfigured to provide optical interrogation signaling, receive sensedoptical interrogation signaling containing information about the one ormore constituents of the output stream and provide the signaling, e.g.,to the signal processor or processing module. The opticalmeasurement/interrogation device may include an optical probe or othersuitable optical sensing device.

The measurement of the one or more constituents of the output stream maybe based upon a chemical interrogation of the output stream.

The chemical interrogation of the output stream may include processing asample/portion of the output stream based upon determining a chemicalcontent of the sample/portion of the output stream.

The apparatus may include a chemical measurement device configured toreceive the sample/portion of the output stream containing the one ormore constituents of the output stream, process the sample/portion andprovide the signaling containing chemical interrogation informationabout the one or more constituents of the output stream, e.g., to thesignal processor or processing module.

The real time feedback control of the dry corn milling process mayinclude providing a control signal to adjust one or more parameters ofthe dry corn milling process, including where the control signal is usedto control the centrifuge, a backend process such as a fermentationprocess, or both.

The one or more parameters may include some combination of thefollowing: a chemical parameter adjustment to one or more sub-processesin the dry corn milling process, including an adjustment to the amount,or timing, or location, of a de-emulsifier dosed to the centrifuge; or alever parameter adjustment of one or more components in the dry cornmilling process, including adjusting a control or throughput lever inthe centrifuge; or a throughput parameter adjustment of one or morecomponents in the dry corn milling process, including adjusting athroughput in the centrifuge; or a flow parameter adjustment in the oneor more components in the dry corn milling process, including adjustinga flow parameter of the centrifuge; or a cycle time parameter adjustmentin the one or more components in the dry corn milling process, includingvarying the cycle time of the centrifuge; or a backflush parameteradjustment in the one or more components in the dry corn millingprocess, including setting up backflush cycles for the centrifuge; or adiversion parameter adjustment in the one or more components in the drycorn milling process, including diverting a portion of the output streamof the centrifuge to another component in the dry corn milling process.

The centrifuge may be configured to receive an input stream containingsyrup/oil and provide a co-product stream containing the one or moreconstituents having corn oil and light, low density solids.

The centrifuge may be configured to receive the input stream and providea second co-product stream containing the one or more constituentshaving corn syrup and higher density solids.

The Raman optical scattering technique may include comparing a sensedoptical scattering signaling in the output stream to a signature opticalscattering signaling stored in an optical scattering database anddetermining the purity of corn oil in the output stream based upon thecomparison.

The real time feedback control of the dry corn milling process mayinclude sensing a desired level of corn oil capture, and providing thecontrol signal to divert a portion of corn oil from the output stream toa distillation process in the dry corn milling process for producingdried distillers grain (DDGs) that goes into animal feed to increase itsfat content.

The real time feedback control of the dry corn milling process mayinclude controlling a split of corn oil and corn syrup provided from thecentrifuge, and determining whether to feed either the corn oil or thecorn syrup back to the centrifuge for further purification, or claim thecorn oil, or sending some portion of the corn oil to a backend processof the dry corn milling process.

According to some other embodiments, the present invention may take theform of a method featuring steps for receiving in a signal processor orsignal processing module signaling containing information about ameasurement of one or more constituents of an output stream from acentrifuge in a dry corn milling process, including to produce Ethanol;and determining in the signal processor or signal processing modulecorresponding signaling containing information about a real timefeedback control of the dry corn milling process, based upon thesignaling received.

The signal processor or signal processor module may take the form of asignal processor and at least one memory including a computer programcode, where the signal processor and at least one memory are configuredto cause the apparatus to implement the functionality of the presentinvention, e.g., to respond to signaling received and to determine thecorresponding signaling, based upon the signaling received.

According to some embodiment, the present invention may take the form ofapparatus comprising means for receiving signaling containinginformation about a measurement of one or more constituents of an outputstream from a centrifuge in a dry corn milling process, including toproduce Ethanol; and means for determining corresponding signalingcontaining information about a real time feedback control of the drycorn milling process, based upon the signaling received, consistent withthat set forth herein.

According to some embodiments of the present invention, the apparatusmay also take the form of a computer-readable storage medium havingcomputer-executable components for performing the steps of theaforementioned method. The computer-readable storage medium may alsoinclude one or more of the features set forth above.

In effect, the present invention is directed at increasing theefficiency of fermentation, distillation and separation via real timeautomation. In operation, the present invention generates real time,on-line separation effectiveness data that provides control targets forprior processing stage variables. These include, but are not limited to,yeast application, fermentation temperature and dwell time, centrifugespeed and maintenance protocol, de-emulsifier application strategy anddosage, and classification of final product quality. Overall, thepresent invention provides a better way for controlling a dry cornmilling process, including to produce Ethanol.

BRIEF DESCRIPTION OF THE DRAWING

The drawing includes FIGS. 1-7, which are not necessarily drawn toscale, as follows:

FIG. 1 shows a block diagram of apparatus, e.g., having a signalprocessor or signal processing module for implementing signal processingfunctionality, according to some embodiments of the present invention.

FIG. 2 is a block diagram of part of a corn milling process, e.g., toproduce Ethanol, that may form part of some embodiments of the presentinvention.

FIG. 3 is a block diagram of another part of a corn milling process,e.g., that may form part of some embodiments of the present invention.

FIG. 4 is a diagram of a centrifuge that may form part of the separationstep shown in FIG. 3, e.g., according to some embodiments of the presentinvention.

FIG. 5A is a separator/centrifuge inlet data process flow diagram, e.g.,according to some embodiments of the present invention.

FIG. 5B is a separator/centrifuge outlet data process flow diagram,e.g., according to some embodiments of the present invention.

FIG. 6 is an evaporator inlet data process flow diagram, e.g., accordingto some embodiments of the present invention.

FIG. 7 is a beer well data process flow diagram, e.g., according to someembodiments of the present invention.

DETAILED DESCRIPTION OF BEST MODE OF THE INVENTION FIG. 1: BasicInvention

By way of example, FIG. 1 shows apparatus 10, e.g. having at least onesignal processor or signal processing module 10 a for implementing thesignal processing functionality according to the present invention. Inoperation, the at least one signal processor or signal processing module10 a may be configured at least to:

-   -   receive signaling containing information about a measurement of        one or more constituents of an output stream from a centrifuge        in a dry corn milling process, including to produce Ethanol; and    -   determine corresponding signaling containing information about a        real time feedback control of the dry corn milling process,        based upon the signaling received.

By way of example, the output stream may include either output stream 20l ₂ or 20 l ₃ of a centrifuge 20 l (FIG. 4) that forms part of a drycorn milling process shown in FIGS. 2-3, consistent with that set forthbelow.

The at least one signal processor or signal processing module 10 a maybe configured to provide the corresponding signaling, e.g., as controlsignaling to provide or implement the real time feedback control of thedry corn milling process, e.g., consistent with that set forth herein.By way of example, the control signaling may provide the real timefeedback control of the dry corn milling process that form part of thatshown in FIGS. 2-7, consistent with that set forth herein.

The functionality of the signal processor or processor module 10 a maybe implemented using hardware, software, firmware, or a combinationthereof. In a typical software implementation, the processor module mayinclude one or more microprocessor-based architectures having amicroprocessor, a random access memory (RAM), a read only memory (ROM),input/output devices and control, data and address buses connecting thesame, e.g., consistent with that shown in FIG. 1, e.g., see element 10b. A person skilled in the art would be able to program such amicroprocessor-based architecture(s) to perform and implement suchsignal processing functionality described herein without undueexperimentation. The scope of the invention is not intended to belimited to any particular implementation using any suchmicroprocessor-based architecture or technology either now known orlater developed in the future, or any particular way of programming thesignal processor to implement the signal processing functionalityaccording to the present invention.

By way of example, the apparatus 10 may also include, e.g., other signalprocessor circuits or components 10 b that do not form part of theunderlying invention, e.g., including input/output modules, one or morememory modules, data, address and control busing architecture, etc. Inoperation, the at least one signal processor or signal processing module10 a may cooperation and exchange suitable data, address and controlsignaling with the other signal processor circuits or components 10 b inorder to implement the signal processing functionality according to thepresent invention. By way of example, the signaling may be received bysuch an input module, provided along such a data bus and stored in sucha memory module for later processing, e.g., by the at least one signalprocessor or signal processing module 10 a. After such later processing,processed signaling resulting from any such determination may be storedin such a memory module, provided from such a memory module along such adata bus to such an output module, then provided from such an outputmodule as the corresponding signaling, e.g., by the at least one signalprocessor or signal processing module 10 a.

The scope of the invention is not intended to be limited to anyparticular implementation using technology either now known or laterdeveloped in the future.

The scope of the invention is intended to include implementing thefunctionality of the processors 10 a as stand-alone processor, signalprocessor, or signal processor module, as well as separate processor orprocessor modules, as well as some combination thereof. By way ofexample, a person skilled in the art would appreciate and understandingwithout undue experimentation, especially after reading the instantpatent application together with that known in the art, e.g., how toimplement suitable signaling processing functionality to receive thesignaling containing information about the measurement of the one ormore constituents of the output stream 20 l ₂ or 20 l ₃ of thecentrifuge 20 l (FIG. 4), e.g., using signal processing techniques thatare either now known or later developed in the future. Consistent withthat described herein, the signaling may include, or take the form of,suitable signaling containing information about an optical or chemicalinterrogation of the output stream 20 l ₂ or 20 l ₃ of the centrifuge 20l (FIG. 4) that contains information about the measurement of the one ormore constituents of the output stream 20 l ₂ or 20 l ₃.

By way of further example, a person skilled in the art would appreciateand understanding without undue experimentation, especially afterreading the instant patent application together with that known in theart, e.g., how to implement suitable signaling processing functionalityto make one or more such determinations, based upon the signalingreceived, using signal processing techniques that are either now knownor later developed in the future. Consistent with that described herein,the signal processing determination may include, or take the form of,implementing one or more of the steps show in FIGS. 5A, 5B, 6 and/or 7.

FIGS. 2-7: Examples of Measurement, Control and Automation in the DryCorn Milling Process

By way of example, and consistent with that shown in FIGS. 2-7, thepresent invention may be implemented by applying measurement, controland automation to a dry corn milling ethanol production process tomaximize the recovery of ethanol and co-products. The dry corn millingprocess ethanol production process is disclosed herein, and may includea dry corn milling process and a measurement, control and automation ofthe separation process, e.g., consistent with that as follows:

Summary of the Dry Corn Milling Process

FIGS. 2 and 3 show steps that form part of the dry corn milling processgenerally indicated as 20 (FIGS. 2) and 30 (FIG. 3).

1. Grain Storage 20 a—In step 20 a, the corn is stored for milling.

2. Corn Milling 20 b—In step 20 b, the corn is ground into powder(“Meal”).

3. Cooking and Liquefaction 20 c, 20 d, 20 e and 20 f—In steps 20 c, 20d, 20 e and 20 f, the dry milled corn is prepared for fermentation. Forexample, the Meal is mixed with water to form a “Mash”, where the starchis converted into dextrose. Ammonia may be added for pH control and as anutrient for yeast. The Mash is cooked to reduce bacteria, the cooledand transferred to a fermenter.

4. Fermentation to create Ethanol (added yeast): In step 20 g, yeast isadded and the sugars are converted into ethanol and CO₂, e.g., so as toform a first co-product.

a. The first co-product: CO₂ produced during fermentation is used forbottling, dry ice, etc.

b. The remainder of the fermented corn mill is further processed insteps 20 h through 20 l.

5. Distillation 20 h: In step 20 h, Ethanol is separated so as to form afirst primary product, and what remains is stillage.

a. The First primary product: In steps 20 h, ethanol produced during thefermentation process is separated from the oily syrup (stillage) in thedistillation process. In steps, 20 i and 20 j, the ethanol is processed(e.g., using a molecular sieve), denatured, and then stored/transportedto the market.

b. The remainder of the distilled corn mill is stillage (syrup/oil mix)that is further processed in steps 20 k through 20 l.

6. The stillage (syrup/oil mix) is processed in step 20 k throughevaporation, tank storage, strainer to a separator/centrifuge in step 20l to separate the components. After evaporation, the stillage is in arange of about 3% to 5% oil.

7. A process aid (de-emulsifier) may be added to the evaporated stillageprior to being provided to the separator/centrifuge process 20 l to aidin the water/oil separation. The separator/centrifuge receives thesyrup/oil 20 l ₁ from the evaporator, which is processed via theseparation/centrifuge process 20 l to provide a first output stream 20 l₂ in the form of a Second co-product and a second output stream 20 l ₃in the form of a third co-product.

a. The Second co-product: Corn oil and light, low density solids areseparated from the syrup and provided as the first output stream 20 l ₂,which may be used to make:

-   -   i. Bio-Diesel.    -   ii. Feed.    -   iii. Corn oil.

b. The Third co-product: Corn Syrup with higher density solids, such asdissolved organics (e.g., sugars), are separated and provided as thesecond output stream 20 l ₃, which may be used to make:

-   -   i. Distillers grains (wet or dry) for feed.

Input/Output Stream Interrogation Techniques

By way of example, one or more of the output streams 20 l ₂ and/or 20 l₃ may be interrogated in order to determine the information about theone or more constituents of the one or more output streams therein. Theinterrogation may include, or take the form of, optical and/or chemicalinterrogation, e.g., by using an optical and/or chemical interrogationdevice 21 a and/or 21 b like that shown in FIG. 4, e.g., configured inrelation to piping/conduit that receives the one or more of the outputstreams 20 l ₂ and/or 20 l ₃. (The lines/arrows in FIG. 4 are understoodto represent piping/conduit having the one or more of the output streams20 l ₂ and/or 20 l ₃ flowing therein.)

By way of further example, an optical interrogation device like element21 a, 21 b may include, or take the form of, an optical probe to provideoptical interrogation signaling and an optical sensor to receive sensedoptical interrogation signaling passing through, or reflected by, anoutput stream like streams 20 l ₂ and/or 20 l ₃, and provide opticalinterrogation signaling containing the optical interrogation informationabout the one or more constituents of the output stream. The opticalinterrogation technique may include, or take the form of, using anear-infrared spectroscopy technique, a Raman scattering technique, aswell as other types or kinds of optical interrogation techniques thatare either now known or later developed in the future.

Alternatively, and by way of further example, a chemical interrogationdevice like element 21 a, 21 b may include, or take the form of, achemical probe to receive a chemical interrogation sample and a chemicalsensor to process the chemical interrogation sample and provide chemicalinterrogation signaling containing the chemical interrogationinformation about the one or more constituents of the output stream. Thechemical interrogation technique may include, or take the form of, usingknown chemical interrogation techniques to determine the present of theone or more constituents set forth herein, as well as other types orkinds of chemical interrogation techniques that may be later developedin the future to determine the present of the one or more constituentsset forth herein.

Alternatively, and by way of still further example, the scope of theinvention is intended to include using other types or kind ofinterrogation techniques to determine the present of the one or moreconstituents set forth herein, that are either now known or laterdeveloped in the future.

By way of example, a similar interrogation device like element 21 a, 21b may be configured or implemented in relation to the input stream 20 l₁ flowing into the separator 20 l, e.g., consistent with that set forthherein.

FIG. 5A and 5B: Measurement, Control and Automation of SeparationProcess

FIG. 5A shows a separator/centrifuge inlet data process flow diagramhaving a flowchart generally indicated as 30 with steps 30 a through 30j, e.g., according to some embodiments of the present invention. Thesteps may include the following:

a step 30 a for receiving data from a separator inlet constituencysensor of the separator 20 l (FIG. 4), e.g., similar to the elements 20a, 20 b configured in relation to the input flow stream 20 l ₁ ofsyrup/oil from the evaporator 20 k into the separator 20 l;

a step 30 b for determining if the oil mass flow is high or low;

-   -   if the oil mass flow is high, then        -   a step 30 c for determining if the water content is optimum;        -   a step 30 d for doing nothing (i.e., no process adjustment)            if the water content is optimum;        -   a step 30 e for adjusting the steam to the evaporator(s) 20            k if the the water content is not optimum (and repeating            step 30 c when needed); alternatively, if the oil mass flow            is low, then        -   a step 30 f for determining if the water content is optimum;        -   a step 30 g for decreasing the throughput through the            separator 20 l if the water content is not optimum, e.g., by            sending control signaling for adjusting a centrifuge flow            level or valve;        -   a step 30 h for adjusting the steam to the evaporator(s) 20            k if the water content is not optimum, e.g., by sending            control signaling for adjusting an evaporator flow level or            valve;        -   a step 30 i for increasing the throughput through the            separator 20 l if the water content is optimum, e.g., by            sending control signaling for adjusting a centrifuge flow            level or valve; and        -   a step 30 j for deferring to the fermenter's accepts sensor            loop if the water content is optimum.

The flowchart 30 may also include a step 32 for cleaning and replacingseparator internals, e.g., based upon the signaling sensed, as well aspart of a routine maintenance procedure.

FIG. 5B is a separator/centrifuge outlet data process flow diagram,having a flowchart generally indicated as 40 with steps 40 a through 40h, e.g., according to some embodiments of the present invention. Thesteps may include the following:

a step 40 a for receiving data from a separator exit constituency sensorof the separator 20 l (FIG. 4), e.g., that may include the elements 20a, 20 b configured in relation to the output stream 20 l ₂ of light cornoil and low density solids, or the output stream 20 l ₃ of heavy cornsyrup and higher density solids, provided from the separator 20 l;

a step 40 b for determining if the oil content is high or low;

-   -   if the oil content is high, then        -   a step 40 c for reducing the de-emulsifier, e.g., by sending            control signaling for adjusting a de-emulsifier flow valve;        -   a step 40 d for increasing the throughout through the            separator 20 l, e.g., by sending control signaling for            adjusting a centrifuge flow level or valve;    -   alternatively, if the oil content is low, then        -   a step 40 e for increasing the de-emulsifier provided to the            separator 20 l (and repeating step 40 b when needed);        -   a step 40 f for decreasing the throughput through the            separator 20 l;        -   a step 40 g for adjusting the Delta P across the separator            20 l;        -   a step 40 h for cleaning and replacing separator internals.

One or more of the steps in FIGS. 5A and 5B may be implemented in wholeor in part by the signal processor or processing module 10 a andcircuits/components 10 b shown in FIG. 1, e.g., including providing thecontrol signaling.

FIG. 6: Measurement, Control and Automation of the Evaporator Process

FIG. 6 shows an evaporator inlet data process flow diagram having aflowchart generally indicated as 50 with steps 50 a through 50 h, e.g.,according to some embodiments of the present invention. The steps mayinclude the following:

a step 50 a for receiving data from an evaporator inlet constituencysensor(s) of the evaporator 20 k (FIG. 3), e.g., similar to the elements20 a, 20 b but configured in relation to the input flow of theevaporator 20 k;

a step 50 b for determining if the oil mass flow is high or low;

-   -   if the oil mass flow is high, then        -   a step 50 c for determining if the ethanol output is high or            low;        -   a step 50 d for making an adjustment in the case for high            mass flow, and no high or low ethanol output (and repeating            step 50 c when needed);        -   a step 50 e for making an adjustment in the case for high            mass flow, and high or low ethanol output;    -   alternatively, if the oil mass flow is low, then        -   a step 50 f for determining if the ethanol output is high or            low;        -   a step 50 g for making an adjustment in the case for low oil            mass flow, and no high or low ethanol output; and        -   a step 50 h for making an adjustment in the case for low oil            mass flow, and high or low ethanol output.

One or more of the steps in FIG. 6 may be implemented in whole or inpart by the signal processor or processing module 10 a andcircuits/components 10 b shown in FIG. 1, including providing thecontrol signaling.

FIG. 7: Measurement, Control and Automation of the Beer Well Process

FIG. 7 shows a beer well data process flow diagram having a flowchartgenerally indicated as 60 with steps 60 a through 60 g, e.g., accordingto some embodiments of the present invention. The steps may include thefollowing:

a step 60 a for receiving data from a beer well exit constituencysensor(s), not shown;

a step 60 b for determining if the ethanol yield is high or low;

-   -   if the ethanol yield is high, then implementing a step 60 c for        doing nothing;    -   alternatively, if the ethanol yield is low, then        -   a step 60 d for determining a CO₂ output to O₂ input ratio;        -   a step 60 e for making an adjustment, if any, including no            adjustment, in relation to the ratio determined; and        -   a step 60 f for increasing or changing the yeast in relation            to the ratio determined.

One or more of the steps in FIG. 7 may be implemented in whole or inpart by the signal processor or processing module 10 a andcircuits/components 10 b shown in FIG. 1.

Examples of Measurement, Control and Automation of Process

By way of example, and consistent with that set forth in FIGS. 5A, 5B, 6and 7, the measurement, control and automation of the overall processmay include implementing one or more of the following:

1. Measurement of Oil Content:

By way of example, the measurement of oil content may include:

-   -   a. Feedstock—In the stillage after evaporation-input to the        cyclone.    -   b. Lite oil and low density solids output of the cyclone 20 l        (FIG. 4).    -   c. De-oiled heavy syrup and high density solids output of the        cyclone.

2. Measurement of Water Content:

By way of example, the measurement of water content may include:

-   -   a. Feedstock—In the stillage after evaporation-input to the        cyclone.    -   b. Lite oil and low density solids output of the cyclone.    -   c. De-oiled heavy syrup and high density solids output of the        cyclone.

3. Measure of Solids Content:

The measure of solids content may include:

-   -   a. Feedstock—In the stillage after evaporation-input to the        cyclone.    -   b. Lite oil and low density solids output of the cyclone.    -   c. De-oiled heavy syrup and high density solids output of the        cyclone.

4. Measure of Sugar Content:

By way of example, the measure of sugar content may include:

-   -   a. At the feed to the fermenter.    -   b. At the discharge of the fermenter.

5. Measure Alcohol Content:

By way of example, the measure of alcohol content may include:

-   -   a. Between fermentation stages.    -   b. At the discharge of the fermenter.

6. Measurement of Air (GVF) Content:

By way of example, the measurement of air (GVF) content may include:

-   -   a. Feedstock—In the stillage after evaporation-input to the        cyclone.    -   b. Lite oil and low density solids output of the cyclone.    -   c. De-oiled heavy syrup and high density solids output of the        cyclone.    -   d. Measurement of the fermentation process-control gas content        to prevent venting and to maximize the recovery of CO₂.

7. Control Based on Measurement:

By way of example, the control based on measurement(s) may include oneor more of the following adjustments:

-   -   a. Adjust the set up and/or cleaning schedule of the separator        based on observed performance.    -   b. Adjust the speed of the dosing pump feeding de-emulsifier        chemistry to the process—As oil purity goes up, de-emulsifier        dose would be decreased and vice-versa.    -   c. Adjust feed rate of process liquid to the separator.    -   d. Adjust the set up and/or cleaning schedule of the fermenter.    -   e. Adjust the dosing of defoamer and/or deaeration chemistry to        the fermenter to control CO₂ production.    -   f. Adjust the dosing of yeast to optimize CO₂ production and/or        reduce measured sugars output to the distillation.    -   g. Adjusting yeast, enzyme addition and air addition to the        fermentation stages based on the measurement of alcohol content        between stages and at the discharge of the last fermenter.    -   h. Adjust dosing of air in the yeast activation phase        (propagators) prior to introduction to the fermentation stage.

Consistent with that set forth herein, one or more of the measurementsmay be used to control and automate the separation process, as well asany of the other processes or sub-processes used to process the milleddry corn, including the fermentation process/stage.

The Scope of the Invention

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, may modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment(s) disclosed herein as thebest mode contemplated for carrying out this invention.

What is claimed is:
 1. Apparatus comprising: a signal processor orprocessing module configured at least to: receive signaling containinginformation about a measurement of one or more constituents of an outputstream from a centrifuge in a dry corn milling process, including toproduce Ethanol; and determine corresponding signaling containinginformation about a real time feedback control of the dry corn millingprocess, based upon the signaling received.
 2. Apparatus according toclaim 1, wherein the signal processor or processing module is configuredto provide the corresponding signaling as control signaling to providethe real time feedback control of the dry corn milling process. 3.Apparatus according to claim 1, wherein the one or more constituents ofthe output stream are selected from the following group: corn oil, cornsyrup, one or more proteins, and leftover yeast solids.
 4. Apparatusaccording to claim 1, wherein the measurement of the one or moreconstituents of the output stream are selected from the following group:the purity of corn oil in the output stream, including the fat content;the purity of the syrup in the output stream, including the carbohydratecontent; the amount of protein in the output stream, including proteinsuseful in animal foods; the amount of water in the output stream; andthe amount of leftover yeast solids in the output stream.
 5. Apparatusaccording to claim 1, wherein the measurement of the one or moreconstituents of the output stream is based upon an optical interrogationof the output stream.
 6. Apparatus according to claim 5, wherein theoptical interrogation of the output stream includes processing opticalsignaling provided and sensed in relation to the output stream. 7.Apparatus according to claim 5, wherein the optical interrogation of theoutput stream includes using a near-infrared spectroscopy technique foroptically interrogating the output stream.
 8. Apparatus according toclaim 5, wherein the optical interrogation of the output stream includesusing a Raman optical scattering technique for optically interrogatingthe output stream.
 9. Apparatus according to claim 1, wherein theapparatus comprises an optical measurement/interrogation deviceconfigured to provide optical interrogation signaling, receive sensedoptical interrogation signaling containing information about the one ormore constituents of the output stream and provide the signaling,including where the optical measurement/interrogation device includes anoptical probe.
 10. Apparatus according to claim 1, wherein themeasurement of the one or more constituents of the output stream isbased upon a chemical interrogation of the output stream.
 11. Apparatusaccording to claim 10, wherein the chemical interrogation of the outputstream includes processing a sample/portion of the output stream basedupon determining a chemical content of the portion of the output stream.12. Apparatus according to claim 11, wherein the apparatus comprises achemical measurement/interrogation device configured to receive thesample/portion of the output stream containing the one or moreconstituents of the output stream, process the sample/portion andprovide the signaling containing the chemical interrogation informationabout the one or more constituents of the output stream.
 13. Apparatusaccording to claim 1, wherein the real time feedback control of the drycorn milling process includes providing a control signal to adjust oneor more parameters of the dry corn milling process, including where thecontrol signal is used to control the centrifuge, a backend process suchas a fermentation process, or both.
 14. Apparatus according to claim 13,wherein the one or more parameters include some combination of thefollowing: a chemical parameter adjustment to one or more sub-processesin the dry corn milling process, including an adjustment to the amount,or timing, or location, of a de-emulsifier dosed to the centrifuge; or alever parameter adjustment of one or more components in the dry cornmilling process, including adjusting a control or throughput lever inthe centrifuge; or a throughput parameter adjustment of one or morecomponents in the dry corn milling process, including adjusting athroughput in the centrifuge; or a flow parameter adjustment in the oneor more components in the dry corn milling process, including adjustinga flow parameter of the centrifuge; or a cycle time parameter adjustmentin the one or more components in the dry corn milling process, includingvarying the cycle time of the centrifuge; or a backflush parameteradjustment in the one or more components in the dry corn millingprocess, including setting up backflush cycles for the centrifuge; or adiversion parameter adjustment in the one or more components in the drycorn milling process, including diverting a portion of the output streamof the centrifuge to another component in the dry corn milling process.15. Apparatus according to claim 1, wherein the centrifuge is configuredto receive an input stream containing syrup/oil and provide a co-productstream containing the one or more constituents having corn oil andlight, low density solids.
 16. Apparatus according to claim 15, whereinthe centrifuge is configured to receive the input stream and provide asecond co-product stream containing the one or more constituents havingcorn syrup and higher density solids.
 17. Apparatus according to claim8, wherein the Raman optical scattering technique includes comparing asensed optical scattering signaling in the output stream to a signatureoptical scattering signaling stored in an optical scattering databaseand determining the purity of corn oil in the output stream based uponthe comparison.
 18. Apparatus according to claim 13, wherein the realtime feedback control of the dry corn milling process includes sensing adesired level of corn oil capture, and providing the control signal todivert a portion of corn oil from the output stream to a distillationprocess in the dry corn milling process for producing dried distillersgrain (DDGs) that goes into animal feed to increase its fat content. 19.Apparatus according to claim 13, wherein the real time feedback controlof the dry corn milling process includes controlling a split of corn oiland corn syrup provided from the centrifuge, and determining whether tofeed either the corn oil or the corn syrup back to the centrifuge forfurther purification, or claim the corn oil, or sending some portion ofthe corn oil to a backend process of the dry corn milling process.
 20. Amethod comprising: receiving in a signal processor or processing modulesignaling containing information about a measurement of one or moreconstituents of an output stream from a centrifuge in a dry corn millingprocess, including to produce Ethanol; and determining in the signalprocessor or processing module corresponding signaling containinginformation about a real time feedback control of the dry corn millingprocess, based upon the signaling received.
 21. A method according toclaim 20, wherein the method also comprises providing from the signalprocessor or processing module the corresponding signaling as controlsignaling to provide the real time feedback control of the dry cornmilling process.
 22. A method according to claim 20, wherein the one ormore constituents of the output stream are selected from the followinggroup: corn oil, corn syrup, one or more proteins, and leftover yeastsolids.
 23. A method according to claim 20, wherein the measurement ofthe one or more constituents of the output stream are selected from thefollowing group: the purity of corn oil in the output stream, includingthe fat content; the purity of the syrup in the output stream, includingthe carbohydrate content; the amount of protein in the output stream,including proteins useful in animal foods; the amount of water in theoutput stream; and the amount of leftover yeast solids in the outputstream.
 24. A method according to claim 20, wherein the measurement ofthe one or more constituents of the output stream is based upon anoptical interrogation of the output stream.
 25. Apparatus comprising:means for receiving in a signal processor or processing module signalingcontaining information about a measurement of one or more constituentsof an output stream from a centrifuge in a dry corn milling process,including to produce Ethanol; and means for determining in the signalprocessor or processing module corresponding signaling containinginformation about a real time feedback control of the dry corn millingprocess, based upon the signaling received.
 26. Apparatus according toclaim 25, wherein the apparatus also comprises means for providing thecorresponding signaling as control signaling to provide the real timefeedback control of the dry corn milling process.